First Semester Syllabus of Mechanic Diesel ( Practical and Theory)

Syllabus for the trade of Mechanic Diesel

First Semester

(Semester code No.

)

Duration: Six Months.

Syllabus for Trade practical and Trade Theory

Week

Trade Practical (27 Hrs/week)

Trade Theory (5 Hrs/week)

No.

1

Familiarisation

with

institute,

Job

Admission & introduction to the trade:

opportunities

in

the

automobile

Introduction  to  the  Course  duration,  course

sector,  Machinery  used  in

Trade.

content,

study

of

the

syllabus.

General

rule

pertaining  to  the

Institute,  facilities  available–

Types of work done by the students

Hostel, Recreation, Medical and Library working

in the shop floor.

hours and time table

2

Practical

related

to

Safety

and

Occupational Safety & Health

Health,

Importance

of

Safety

and

general

Importance

of

maintenance

and

Precautions  to  be observed  in

the

shop.

Basic

cleanliness of

Workshop.

first  aid,

safety  signs

-

for  Danger,  Warning,

caution & personal safety message. Safe handling

Interaction

with

health  centre

and

of  Fuel

Spillage,

Fire

extinguishers  used  for

fire service station to provide demo

different types of fire. Safe disposal of toxic dust,

on First aid and Fire safety, Use of

safe  handling  and  Periodic  testing  of  lifting

fire extinguishers.

equipment,  Authorization  of  Moving  &  road

Demonstration on safe handling and

testing vehicles.

Periodic testing of lifting equipment,

Energy conservation-Definition, Energy

and Safety disposal of Used engine

Conservation Opportunities (ECOs)-Minor ECos

oil.

and Medium ECOs, Major ECOs), Safety disposal

Energy  saving  Tips  of  ITI  electricity

of Used engine oil, Electrical safety tips.

Usage

3-5

Practice using all marking aids, like

Hand & Power Tools:-

steel   rule   with   spring   calipers,

Marking   scheme,   Marking   material-chalk,

dividers,

scriber,

punches,

Chisel

Prussian blue. Cleaning tools- Scraper, wire brush,

etc.,

Emery paper, Description, care and use of Surface

plates,  steel  rule,

measuring

tape,  try

square.

Layout a work piece- for line, circle,

Calipers-inside

and

outside.

Dividers,

surface

arcs and circles.

gauges,

scriber,

punches-prick

punch,

center

Practice to measure a wheel base of a

punch, pin punch, hollow punch, number and letter

vehicle with measuring tape.

punch.  Chisel-flat, cross-cut.  Hammer- ball  pein,

Practice

to

measure

valve

spring

lump,   mallet.   Screw   drivers-blade   screwdriver,

tension using spring tension tester

Phillips

screw

driver,

Ratchet

screwdriver.

Allen

key,  bench  vice

&

C-clamps,

Spanners-

ring

Practice

to

remove

wheel  lug

nuts

spanner,

open

end  spanner  &

the  combination

with use of an air impact wrench

spanner, universal adjustable open end spanner.

Practice on General workshop tools

Sockets  &  accessories,  Pliers  -  Combination

& power tools.

pliers, multi grip, long nose,

flat-nose, Nippers

or pincer pliers, Side cutters, Tin snips, Circlip

pliers, external circlips pliers. Air impact wrench,

air  ratchet,  wrenches-  Torque  wrenches,  pipe

wrenches, car jet washers Pipe flaring & cutting

tool, pullers-Gear and bearing.

6&7	Measuring practice on Cam height,					Systems of measurement, Description, care  &
	Camshaft		Journal	dia,	crankshaft	use   of   -   Micrometers-   Outside   and   depth
	journal  dia,  Valve  stem  dia,  piston					mirometer,  Micrometer  adjustments,	Vernier
	diameter,  and  piston  pin  dia  with					calipers, Telescope gauges, Dial bore gauges, Dial
	outside Micrometers.					indicators, straightedge, feeler gauge,  thread pitch
	Measuring practice on the height of					gauge, vacuum gauge, tire pressure gauge.
	the  rotor  of  an  oil  pump  from  the
	surface of the housing or any other
	auto	component  measurement  with
	depth micrometer.
	Measuring practice on valve spring
	free length.
	Measuring practice on cylinder bore,
	Connecting rod bore, inside diameter
	(ID)  of  a  camshaft  bearing  with
	Telescope gauges.
	Measuring practice on cylinder bore
	for taper and out-of-round with Dial
	bore gauges.
	Measuring practice to measure wear
	on  crankshaft  end  play,  crankshaft
	run  out,  and  valve  guide  with  dial
	indicator.
	Measuring  practice  to  check  the
	flatness  of  the  cylinder  head  is
	warped or twisted with straightedge
	is used with a feeler gauge.
	Measuring practice to check the end
	gap	of  a	piston	ring,	piston-to-

cylinder wall clearance with feeler gauge.

Practice to check engine manifold vacuum with vacuum gauge. Practice to check the air pressure inside the vehicle tires is maintained

at the recommended setting.
8 & 9   Practice	on    General	cleaning,	Fasteners-  Study  of  different  types  of  screws,
checking and use of nut,		bolts, &	nuts, studs & bolts, locking devices, Such as lock
studs etc.,			nuts, cotter, split pins, keys, circlips, lock rings,
			lock washers and locating where they are used.
Removal  of  stud/bolt  from  blind			Washers & chemical compounds can be used to
hole.			help secure these fasteners. Function of Gaskets,
			Selection of materials for gaskets and packing, oil
Practice   on   cutting   tools   like			seals.
Hacksaw, file, chisel, Sharpening of			Cutting tools :- Study of different type of cutting
Chisels,	centerpunch,	safety
			tools  like Hacksaw,  File- Definition, parts  of  a
precautions while grinding.
			file, specification, Grade, shape, different type of

7

Practice on Hacksawing and filing to

cut  and  uses.,  OFF-hand  grinding  with  sander,

given dimensions.

bench  and  pedestal  grinders,  safety  precautions

while grinding.

Limits, Fits & Tolerances:-Definition of limits,

fits  &  tolerances  with  examples  used  in  auto

components

10 &

Practice  on  Marking

and

Drilling

Drilling  machine  -  Description  and  study  of

11

clear and Blind Holes, Sharpening of

Bench type Drilling machine, Portable electrical

Twist Drills Safety precautions to be

Drilling  machine,

drill  holding

devices,  Work

Holding devices, Drill bits.

observed

while

using

a

drilling

Taps

and

Dies:

Hand

Taps

and

wrenches,

machine.

Practice

on

Tapping

a

Calculation of Tap drill sizes for metric and inch

Clear and

Blind

Hole,

Selection

of

taps. Different type of Die and Die stock. Screw

tape  drill  Size,  use  of  Lubrication,

extractors.

Hand Reamers – Different Type of

Use of stud extractor.

hand  reamers,  Drill  size  for  reaming,  Lapping,

Cutting  Threads  on  a  Bolt/  Stud.

Lapping abrasives, type of Laps.

Adjustment   of   two   piece   Die,

Reaming  a  hole/  Bush  to  suit  the

given  pin/  shaft,  scraping  a  given

machined surface.

12

Practice

on

making

Rectangular

Sheet metal - State the various common metal

Tray.

Sheets used in Sheet Metal shop

Pipe bending, Fitting nipples unions

Sheet

metal  operations

-

Shearing,

bending,

Drawing, Squeezing

in pipes.  Soldering and Brazing of

Sheet metal joints - Hem & Seam Joints Fastening

Pipes.

Methods  -  Riveting,  soldering,  Brazing.  fluxes

used on common joints. Sheet and wire-gauges.

The blow lamp- its uses and pipe fittings.

13

Practice

in

joining

wires

using

Basic  electricity,  Electricity  principles,  Ground

soldering

Iron,

Construction

of

connections,   Ohm's   law,   Voltage,   Current,

simple electrical circuits, Measuring

Resistance, Power, Energy. Voltmeter, ammeter,

Ohmmeter Mulitmeter, Conductors & insulators,

of  current,  voltage

and  resistance

Wires, Shielding, Length vs. resistance, Resistor

using

digital

multimeter,

practice

ratings

continuity  test  for  fuses,  jumper

wires, fusible links, circuit breakers.

14

Diagnose

series,

parallel,

series-

Fuses   &   circuit   breakers,   Ballast   resistor,

parallel

circuits

using

Ohm’s

law,

Stripping wire insulation, cable colour codes and

Check

electrical

circuit

with

a

test

sizes,

Resistors  in

Series

circuits

,  Parallel

circuits and Series-parallel circuits,

Electrostatic

lamp,  perform  voltage

drop

test

in

effects, Capacitors and its applications, Capacitors

circuits

using

multimeter,  measure

in

series

and

parallel.

current

flow

using

multimeter

/ammeter,  use  of  service  manual

wiring diagram for troubleshooting.

15

Cleaning and topping up of a lead

Description

of  Chemical

effects,

Batteries  &

acid

cells,

Lead acid batteries

& Stay Maintenance

battery,

Testing

battery

with

Free (SMF)

batteries, Magnetic effects,  Heating

8

hydrometer,

effects,   Thermo-electric   energy,   Thermisters,

Connecting battery to a charger for

Thermo couples, Electrochemical energy, Photo-

battery

charging,

Inspecting

&

voltaic

energy,

Piezo-electric

energy,

testing  a  battery  after  charging,

Electromagnetic  induction,

Relays,

Solenoids,

Measure and Diagnose the cause(s)

Primary  &  Secondary  windings,  Transformers,

of  excessive  Key-off  battery  drain

stator and rotor coils.

(parasitic  draw)  and  do  corrective

action. Testing of relay and solenoids

and its circuit.

16

Identify  and  test  power  and  signal

Basic   electronics:   Description   of

Semi

connectors

for

continuity,

Identify

conductors,    Solid    state    devices-    Diodes,

and  test

different

type

of

Diodes,

Transistors, Thyristors, Uni Junction

Transistors (

UJT),  Metal

Oxide

Field

Effect  Transistors  (

NPN

&

PNP

Transistors

for

its

MOSFETs),

Logic gates-OR, AND & NOT and

functionality,

Logic gates using switches.

Construct   and   test   simple   logic

circuits OR, AND & NOT and Logic

gates using switches.

17&

Practice to make straight beads and

Introduction to welding and Heat Treatment

18

Butt, Lap & T joints Manual Metal

Arc Welding.

Welding processes – Principles of Arc welding, brief

Setting of Gas welding flames,

description,

classification  and

applications.

Manual

Metal  Arc

welding

-principles,  power

sources,

practice to make a straight beads and

electrodes, welding parameters, edge preparation

joints

Oxy – Acetylene welding

& fit up and welding techniques; Oxy – Acetylene

Film on Heat treatment process

welding   -   principles,   equipment,   welding

parameters, edge preparation & fit up and welding

techniques;.

Heat Treatment Process– Introduction, Definition

of  heat  treatment,  Definition  of  Annealing,

Normalizing,  Hardening  and  tempering.  Case

hardening,  Nitriding,  Induction  hardening  and

Flame   Hardening   process   used   in   auto

components with examples.

19 &

Practice on Liquid penetrant testing

Non-destructive Testing Methods-

Importance

20

method and Magnetic particle testing

of  Non-Destructive  Testing  In  Automotive

method.

Industry, Definition of NDT, Liquid  penetrant

Identification

of

Hydraulic

and

and Magnetic

particle testing method – Portable

pneumatic

components

used

in

Yoke method

vehicle.

Introduction  to  Hydraulics  &  Pneumatics:  -

Tracing   of   hydraulic   circuit   on

Definition   of   Pascal   law,   pressure,   Force,

hydraulic

jack,

hydraulic

power

viscosity. Description, symbols and application in

steering,

and

Brake

circuit.

automobile  of  Gear  pump-Internal  &  External,

Identification  of  components  in  Air

single  acting,  double  acting  &  Double  ended

brake systems.

cylinder; Directional control valves-2/2, 3/2, 4/2,

4/3 way valve, Pressure relief valve, Non return

valve, Flow control valve used in automobile.

9

							Pneumatic Symbols, Description and function of
							air  Reciprocating  Compressor.  Function  of  Air
							service unit (FRL-Filter, Regulator & Lubricator).
21	Identification		of	different	type	of	Auto  Industry -  History,  leading  manufacturers,
	Vehicle.						development in automobile industry, trends, new
							product. Brief about Ministry of Road transport &
	Demonstration			of	vehicle
							Highways,
	specification data;
							The  Automotive  Research  Association  of  India
	Identification of vehicle information
							(ARAI), National Automotive Testing and R&D
	Number	(VIN).		Demonstration		of	Infrastructure  Project  (NATRIP),  &  Automobile
	Garage, Service station equipments.-						Association.
	Vehicle hoists – Two post and four						Definition:  -  Classification  of  vehicles  on  the
	post  hoist,		Engine  hoists,   Jacks,
							basis of load as per central motor vehicle rule,
	Stands.						wheels, final drive, and fuel used, axles, position
							of  engine  and  steering  transmission,  body and
							load. Brief description and uses of Vehicle hoists
							– Two post and four post hoist, Engine hoists,
							Jacks, Stands.
22-23		In-plant Training
24-25		Revision and Test
26		NCVT Exam

	1st Semster
	Workshop Calculation and Science
	Syllabus for the trade of
	1.   Mechanic Diesel
Week	Workshop calculation and
No.	Science (3 Hrs/week)
1	Units, Derived and fundamental, types of system FPS, CGS, MKS and their conversion.
	Metric weights and measurements, units conversion factors
2	Fractions- Addition and subtraction, Fractions and whole numbers, Combined addition
	and subtraction, Multiplication and division of fractions. Operations in problems involving
	fractions.
3	Order of performing (BODMAS) Mathematical operators ,	Integers – Rules for dealing
	with integers, Addition, subtraction, Multiplication and division.
4 & 5	Ratio and proportion. Percentages, Examples of ratios in Automotive technology
6	profit and loss, Discount .
7	simple interest and compound interest
8	depreciation calculation
9-10	Time and work problem , Time and distance, clocks and calendar,
11	Brief description of manufacturing process of steel, and aluminum
12	Meaning of elasticity, malleability, brittleness, hardness, compressibility & ductility and
	their examples , Properties and uses of cast iron, ferrous metal, gray cast iron, white cast
	iron, wrought iron, and plain carbon steel, high speed steel and alloy steel.
13	Properties and uses in  automobile  industries- copper, zinc, lead, tin, aluminum, brass,
	bronze,  solder  bearing  metals,  timber  and  rubber.  Nylon,  P.V.C.,  PP  (poly prop  line,
	polymer).
14-15	Materials – Stress, strain,- Definition of Stress, Types of stress- Tensile, compressive,
	shear , Examples of the three basic stresses in automotive components , calculation  of stress
	and strain in automotive application, Stress raisers, Strain-, Tensile, compressive, Shear
	strain, Tensile strength,  Factor of safety, Torsional stress, Strain energy.
16	Definition of cold working and Hot working and its properties on sheet metal. Advantage of
	Deep drawing material. Importance of Iron- carbon diagram in heat treatment process.
17	Different Type of cutting fluids and their properties. Calculation of cutting speed, feed and
	drilling time.
18-19	Forces – Definition of  Force, Types of force -examples,– Direct forces, Attractive forces,
	Explosive forces,  Describing forces,  Graphical representation of a force, Addition of
	forces,  Parallelogram  of  forces  ,Triangle  of  forces,	Resolution  of  forces,  Mass,
	Equilibrium, Pressure, Pressure in hydraulic systems, Hooke’s law, Practical applications.
20-21	Work energy, power– Definition and calculation of Work, Power and  Work done by a
	torque, Definition and calculation of Energy -Potential energy, Chemical energy,
	Conservation of energy, Energy equation, Kinetic energy, Energy of a falling body, Kinetic
	energy of rotation.

	1st Semester Engineering Drawing
	Syllabus for the trade of Mechanic Diesel
Week	Engineering Drawing (3 Hrs/week)
No.	1st Semester
1	Importance of engineering drawing as a communication medium, different types of
	drawing - Machine Drawing, Production Drawing, Part Drawing, Assembly
	Drawing, Drawing instruments, equipment and materials and their uses
2&3	Scales - Recommended scales, reduced & enlarged Drawing Sheet sizes: A0, A1,
	A2, A3, A4, A5, Layout of drawing sheet, sizes of title block and its contents. Using
	drawing instruments to draw straight lines, rectangles, squares, circles, polygons.
4&5	Lettering and Dimensioning - Types of Lettering, Guide Lines for lettering,
	Recommended sizes of letters and numbers, Single stroke letters, Dimensioning -
	rules and systems of dimensioning – dimensioning a given drawing.
6&7	Identify the alphabet of lines- Read and Interpret the meaning of various line types
	with examples- Object Lines, Hidden Lines, Center Lines, Phantom Lines,
	Dimension Lines, Extension Lines, Leaders, Break Lines -Long-break Line, Round,
	Solid, Hollow Cross Section, Section Lines – Common Manufacturing Materials,
	Cutting Plane Lines
8-11	Geometric Construction - Bisecting a line - perpendiculars - parallel lines - division
	of a line; Angles - bisection, trisection, Tangent lines touching circles internally and
	externally Polygons - Regular polygons - circumscribed and inscribed in circles.
	Conic sections - Definitions of focus, directrix, eccentricity, Construction of Ellipse
	by Concentric circles method, Construction of parabola by rectangular method.
12&13	Orthographic Projection - Definition - Planes of Projection - Four quadrants –
	Reference Line, First angle projection - Third angle projection.
14-17	Isometric Projection - Definition - Isometric axes, lines and planes, Isometric Scale
	- Isometric view. Drawing of isometric views of plane figures, Drawing of isometric
	views of prisms and pyramids, Drawing of isometric view of cylinders and cones
18-21	Development of Surfaces - Need for preparing development of surface, Concept of
	true length - Principal methods of development, Development of simple solids like
	cubes, prisms, cylinders, pyramids, cones.